US6957761B2 - Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube - Google Patents

Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube Download PDF

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Publication number
US6957761B2
US6957761B2 US10/409,266 US40926603A US6957761B2 US 6957761 B2 US6957761 B2 US 6957761B2 US 40926603 A US40926603 A US 40926603A US 6957761 B2 US6957761 B2 US 6957761B2
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Prior art keywords
tubular structure
rpm
rotating
tubular
outlet port
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US10/409,266
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English (en)
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US20040200883A1 (en
Inventor
William D. Staheli
Gregory J. Lang
Kenneth J. Clark
Robert E. Lewis
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Autoliv ASP Inc
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Autoliv ASP Inc
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Priority to US10/409,266 priority Critical patent/US6957761B2/en
Assigned to AUTOLIV ASP, INC. reassignment AUTOLIV ASP, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CLARK, KENNETH J., LANG, GREGORY J., LEWIS, ROBERT E., STAHELI, WILLIAM D.
Priority to JP2006509738A priority patent/JP4891067B2/ja
Priority to DE112004000593T priority patent/DE112004000593T5/de
Priority to PCT/US2004/010557 priority patent/WO2004091840A2/en
Publication of US20040200883A1 publication Critical patent/US20040200883A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/26—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow
    • B60R21/264—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow using instantaneous generation of gas, e.g. pyrotechnic
    • B60R21/2644—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow using instantaneous generation of gas, e.g. pyrotechnic using only solid reacting substances, e.g. pellets, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/129—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding specially adapted for particular articles or workpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0672—Spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1226—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5324—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially annular, i.e. of finite length
    • B29C66/53245—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially annular, i.e. of finite length said articles being hollow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/26—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow
    • B60R21/264—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow using instantaneous generation of gas, e.g. pyrotechnic
    • B60R21/2644—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow using instantaneous generation of gas, e.g. pyrotechnic using only solid reacting substances, e.g. pellets, powder
    • B60R2021/2648—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow using instantaneous generation of gas, e.g. pyrotechnic using only solid reacting substances, e.g. pellets, powder comprising a plurality of combustion chambers or sub-chambers

Definitions

  • the present invention relates to methods of inertial welding. More specifically, the present invention relates to inertial welding methods for attaching a conical component to a side of a pipe or tube.
  • Friction welding is a technology used to join metal or other thermoplastic components using heat generated by friction between the components. This technology is often used to join a tube, solid rod, or other symmetrical object to another component. Generally, the needed friction between the parts is obtained by rotating one part and pressing it against the other, which is held stationary. The heat generated by the resulting friction softens the material of the parts, and the softened materials may then be forced together and allowed to become rigid, thus forming a stable weld.
  • This general method is commonly used to weld a tube or pole to a flat surface, to weld two poles or tubes end-to-end, and to create butt joints.
  • the part being rotated is generally substantially symmetrical, and is rotated about its axis of symmetry. This provides stability during the rotation of the part.
  • the face of the part being rotated and the receiving face of the other part are generally flat, planar surfaces such that when placed in contact, there is a constant interface between the rotating part and the surface to which it is being joined.
  • the part being rotated may be solid, such as a metallic rod, or may be hollow, such as a metal pipe or tube. Both of these configurations yield a stable rotation and a constant interface between the rotating part and the weld surface.
  • the non-rotating part to which the substantially symmetrical component is being welded may also be symmetrical, as when two rods or tubes are being joined end-to-end.
  • the components may be asymmetrical.
  • the receiving component may simply include a flat surface to which a rotatable component is to be joined.
  • the receiving component may include an aperture against which the rotatable part is pressed.
  • the parts to be welded are first aligned such that the surfaces to be joined are substantially parallel.
  • the part to be rotated is then rotated at a specific speed and pressed against the opposite surface with a predetermined pressure.
  • the contact and rotation of the parts generates sufficient heat to render plastic the material of the parts at their interface.
  • the rotation of the parts sweeps outward some of the material at the interface of the two components. This action helps to compensate for a less-than optimal interface by removing detrimental surface features. It also rids the interface of oxidized materials or impurities that could weaken the weld.
  • the material driven from the interface builds up and cools about the weld, forming a structure called a “weld flash” about the interface of the two components.
  • the weld flash is desirably uniformly distributed about the joint, and provides a smooth, aesthetically-acceptable surface at the weld.
  • the present invention provides a method for welding a conical component into an elliptically-shaped hole in the wall of a pipe or tube.
  • the present invention provides a method of welding an outlet port into a tubular airbag inflator body to form an airbag inflator.
  • a first step of the method of the invention is to provide a first tubular structure having a conical contact face.
  • the tubular structure is an outlet port for an airbag inflator.
  • This first tubular structure is generally symmetrical and has an axis of symmetry about which it may be rotated.
  • a next step of the methods of the invention is to provide a second tubular structure having a contact orifice for receiving the first tubular structure.
  • the second tubular structure is an airbag inflator body or other similar tubular structure.
  • the contact orifice of the second tubular structure is generally positioned on a rounded outside face of the second tubular structure.
  • the contact orifice is generally elliptical in shape, and is defined by a major diameter and a minor diameter.
  • the major diameter of the elliptical contact orifice of the second tubular structure is generally positioned in a single plane along the surface of the second tubular structure. If the second tubular structure is an elongated symmetrical tube, the major diameter is generally placed substantially parallel to the axis of symmetry.
  • the minor diameter is positioned substantially perpendicular to the major diameter. As a result, the minor diameter travels through the interior of the tubular structure rather that strictly along its surface like the major diameter.
  • the contact orifice may be placed on a flattened portion of the second tubular structure. This results in a contact orifice which is circular when the flattened region is as wide as or wider than the outlet port, and a partially-circular, partially-elliptical shape when the flattened region is narrower than the outlet port.
  • a next step of the method is to align the components such that the conical contact face of the first tubular structure is directed into the elliptical contact orifice of the second tubular structure. This generally aligns the two structures in a substantially perpendicular manner, and results in the conical contact face contacting the elliptical contact orifice as the structures are brought together.
  • the first tubular structure is rotated about its axis of symmetry.
  • the speed of rotation may be selected to provide sufficient energy to the rotating part to generate sufficient friction to soften the parts enough to form a weld.
  • the rotating part is then pressed against the second tubular structure, which is held stationary. The pressure further helps to generate the friction, and to provide a weld once softening has occurred.
  • the friction created at the contact faces of the first and second tubular structures generates heat, rendering the contact surfaces plastic.
  • the plastic surfaces then form a weld, uniting the first and second tubular structures.
  • the method uses a single set of rotation and pressure steps to create the weld.
  • the first tubular structure is rotated at a speed of from about 6500 rpm to about 11000 rpm.
  • the first tubular structure is pressed against the second with a pressure of from about 900–1200 psi.
  • the method of the invention uses a two-step method in which the first tubular structure is first rotated at an outset rate and placed in contact with the second structure at an onset pressure. After a period of time, the rate of rotation is changed to a weld rate, and the pressure to a weld pressure.
  • the onset rate of rotation varies from about 6350 rpm to about 9925 rpm.
  • the onset pressure is generally from about 300 psi to about 360 psi.
  • the weld rotation rate is from about 6000 rpm to about 9500 rpm.
  • the weld pressure during the second step is from about 1000 psi to about 1200 psi.
  • a final step involves holding the two structures in place in order to allow the weld to cure.
  • This step generally includes holding the structures in place for a period of at least about 0.5 seconds. This step generally lasts from about 0.5 to about 2 seconds.
  • the invention further includes airbag inflators produced using the methods of the invention.
  • the airbag inflators of the invention include inflators having an outlet port and a tubular inflator body joined by the friction welding techniques of the invention.
  • FIG. 1A is a perspective view of a first embodiment of an airbag inflator capable of being assembled using the friction welding methods of the invention
  • FIG. 1B is a lateral cross-sectional view of the airbag inflator of FIG. 1A taken along line 1 B— 1 B of FIG. 1A ;
  • FIG. 1C is a longitudinal cross-sectional view of the airbag inflator of FIG. 1A taken along line 1 C— 1 C of FIG. 1A with the outlet port shown separated from the inflator body;
  • FIG. 2A is a perspective view of a second embodiment of an airbag inflator assembled using the friction welding methods of the invention
  • FIG. 2B is a an end view of the assembled airbag inflator of FIG. 2A ;
  • FIG. 2C is a longitudinal cross-sectional view of the assembled airbag inflator of FIG. 2A taken along line 2 C— 2 C of FIG. 2B ;
  • FIG. 2D is an isolated cross-sectional view of an alternative embodiment of the outlet port of the airbag inflator of FIG. 2A ;
  • FIG. 2E is an isolated cross-sectional view of an alternative embodiment of the outlet port of the airbag inflator of FIG. 2A ;
  • FIG. 3 is a perspective view of another embodiment of an airbag inflator assembled using the friction welding methods of the invention.
  • Friction welding generally provides high-quality welds, and is very susceptible to use in assembly-line manufacturing. Additionally, friction welding methods such as the methods of the invention provide welds having aesthetically-pleasing and smooth weld flashes, thus avoiding the need for additional processing after welding.
  • the term “friction welding” is used to denote a process by which metallic or thermoplastic objects are joined by creating friction between them to generate heat and soften the objects sufficiently to form a weld. In some applications, friction is generated between the objects by rotating one object relative to the other and pressing them together. Further, the term “inertial welding” is used to describe a form of friction welding in which a flywheel or other equivalent device is used to provide kinetic energy which is directed to weld the two thermoplastic members together.
  • the present invention provides methods for friction welding a tubular structure with a conical contact surface to an orifice placed in the side of a second tubular structure. These methods involve rotating the first tubular structure and pressing it into the orifice of the second structure to cause it to form a weld.
  • the orifice is substantially elliptical in shape.
  • the orifice is placed into a flattened region of the second tubular structure, resulting in an orifice having a constant radius, and thus in some regions, a circular geometry in addition to the elliptical regions.
  • the methods of the invention are useful in many contexts. For example, the methods are useful in fusing components such as outlet ports into airbag inflators.
  • the invention further includes airbag inflators constructed using the methods of the invention.
  • the invention further includes methods of constructing airbag inflators using the friction welding methods disclosed herein.
  • FIG. 1A a perspective view of components of an airbag inflator 10 capable of being assembled using the friction welding methods of the invention is shown.
  • the airbag inflator 10 is shown with the outlet port 50 placed in abutment to the inflator body 11 . This is the alignment of the parts 11 , 50 prior to being welded using the method of the invention.
  • the inflator 10 is composed of an inflator body 11 having gas chambers 16 a, 16 b that are connected by a central chamber 18 and capped by end caps 12 a, 12 b.
  • the inflator body 11 further includes an elliptical outlet orifice 20 into which the outlet port 50 may be welded using the methods of the invention. This weld would be visible as an external weld flash.
  • the inflator 10 is configured to hold a pressurized gas, mixture of gases, gas generant, or other compound or system for providing an inflation gas for an inflatable airbag (not shown). Further, the inflator 10 is configured to controllably release that inflation gas to inflate an airbag.
  • the outlet port 50 is shown to include an outlet housing 52 comprising outlet orifices 54 .
  • the outlet housing 52 may enclose a diffuser 56 .
  • the housing 52 is attached to a port body 60 having a conical contact surface 62 .
  • the conical contact surface 62 of the outlet port 50 contacts the elliptical outlet orifice 20 of the inflator body 11 during the welding process of the invention.
  • FIG. 1B is a lateral cross-section view of the inflator 10 of FIG. 1A taken at line 2 A— 2 A of FIG. 1A .
  • FIG. 1B shows the outlet port 50 placed into abutment with the inflator body 11 as it would be positioned for welding prior to its attachment to the inflator body 11 .
  • FIG. 1B thus serves as an illustration of the configuration of the components prior to subjecting them to the welding method of the invention.
  • the view of FIG. 1B first shows the outlet port 50 in a cross-sectional view.
  • the outlet port 50 comprises a port body 60 which is a substantially rigid member having a conical contact surface 62 .
  • the port body 60 is a generally tubular structure, including an outlet passage 58 that allows gas to pass from the inflator body 11 into the outlet port 50 .
  • the outlet passage 58 is continuous with the outlet housing 52 of the outlet port 50 , which is attached to the port body 60 .
  • the outlet housing 52 features at least one outlet orifice 54 for releasing gas transmitted through the outlet passage 58 into the surrounding environment.
  • the outlet port 50 may additionally include a diffuser 56 for regulating the flow of exiting gas.
  • the outlet port 50 is shown to be configured to be attached to the inflator body 11 at the elliptical outlet orifice 20 .
  • the outlet port is shown having a conical contact surface 62 which interfaces with the elliptical outlet orifice 20 .
  • This conical contact surface 62 has an included angle 67 .
  • the included angle 67 is an angle which may be large, resulting in a relatively flat conical contact surface 62 , or small, resulting in a very steep conical contact surface 62 .
  • the included angle 67 is an angle of from about 30 degrees to about 90 degrees. In some presently-preferred embodiments, the included angle is from about 60 degrees to about 90 degrees.
  • the conical contact surface 62 varies in diameter 53 over its height. Specifically, the conical contact surface 62 has a diameter 63 ranging from a large diameter 64 to a narrow diameter 66 .
  • the conical contact surface 62 contacts the elliptical outlet orifice 20 of the inflator body 11 over a range of its surface referred to as the contact face 68 .
  • the contact face 68 is a region which contacts the edges of the elliptical contact orifice 20 when the outlet port 50 is inserted into the inflator body 11 .
  • the contact face 68 is a substantially linear region of the conical contact surface 62 .
  • the contact face 68 is a band positioned about the conical contact surface 62 . This region forms the weld 32 during the method of the invention.
  • FIG. 1B further shows the inflator body 11 which attaches to the outlet port 50 .
  • the inflator body 11 includes an elliptical outlet orifice positioned in a narrowed central chamber 18 and a gas chamber 16 a that is closed and sealed with an end cap 12 a.
  • the narrowed central region 18 allows use of a smaller elliptical outlet orifice 20 , and thus a smaller region over which to form the weld 32 .
  • the inflator body 11 may alternatively have a uniform size, omitting the narrowed central chamber 18 .
  • FIG. 1B also shows the geometry of the elliptical outlet orifice 20 . Specifically, FIG. 1B shows the minor diameter 24 of the elliptical outlet orifice 20 .
  • This minor diameter 24 may be obtained and positioned by projecting the outlet port 50 against the end of the inflator body 11 at the height at which the outlet port 50 is desired to be placed.
  • the minor diameter 24 obtained also generally corresponds to a small diameter 66 of the outlet port 50 reflecting an approximate lower boundary of the contact face 68 .
  • FIG. 1C yet another view of the inflator 10 of FIG. 1A is shown. Specifically, FIG. 1C shows the inflator 10 of FIG. 1A in a longitudinal cross-sectional view taken at line 1 C— 1 C of FIG. 1A .
  • the outlet port 50 is shown separated from the inflator body 11 .
  • the inflator 10 is shown to comprise an inflator body 11 , and an outlet port 50 .
  • the inflator body 11 of the inflator 10 has gas chambers 16 a, 16 b connected by a narrowed central chamber 18 , as seen in the above Figures.
  • the inflator body 11 further includes an elliptical outlet orifice 20 to receive the outlet port 50 .
  • FIG. 1C further clarifies the geometry of the elliptical outlet orifice 20 .
  • FIG. 1C shows the major diameter 22 of the elliptical outlet orifice 20 .
  • This major diameter 22 may be obtained and positioned by projecting the outlet port 50 against the side of the inflator body 11 at the height at which the outlet port 50 is desired to be placed.
  • the major diameter 22 obtained also generally corresponds to large diameter 68 of the outlet port 50 reflecting an approximate upper boundary of the contact face 68 .
  • the inflator 10 further includes an outlet port 50 having an outlet passage 58 continuous with interior of the inflator body 11 when attached to the inflator body 11 .
  • the outlet passage 58 travels through the port body 60 and terminates in the outlet housing 52 . Gases passing through the passage 58 may then exit through outlet orifices 54 .
  • the outlet port 50 also includes a diffuser 56 through which gases must pass prior to exiting through the outlet orifices 54 .
  • the outlet port 50 also includes a conical contact surface 62 that interfaces with the elliptical outlet orifice 20 of the inflator body 11 . As discussed above, the conical contact surface 62 has a diameter 63 that varies from a large diameter 64 to a small diameter 66 .
  • the inflator 110 includes an inflator body 111 and an outlet port 150 .
  • the inflator body 111 is here a tubular component having a substantially uniform diameter 113 with ends sealed with end caps 112 a, 112 b.
  • the inflator body 111 may include gas chambers 116 a, 116 b and a connecting chamber 118 . These chambers 116 a, 116 b, 118 may be partitioned or may be continuous with each other. As in FIGS.
  • the inflator body 111 also includes an elliptical outlet orifice 120 provided in an outside surface of the inflator body 111 .
  • the orifice 120 may be cut, machined, punched, or otherwise provided in the inflator body 111 .
  • the outlet port 150 illustrated in FIG. 2A is wider than outlet port 50 of FIGS. 1A–1C .
  • the outlet port 150 has an outlet port housing 152 with outlet orifices 154 .
  • the outlet port 150 may additionally include a diffuser 156 .
  • Port 150 has a conical contact surface 162 defined by an internal angle 167 (shown in FIG. 2C ) that is larger in this embodiment than the internal angle 67 of FIGS. 1A–1C .
  • the outlet port 150 is also wider than the outlet port 50 of FIGS. 1A–1C , having a large diameter 164 and a small diameter 166 .
  • the port 150 is configured to be set low into the inflator body 111 .
  • the inflator body 111 includes an elliptical orifice 120 wider than 20 of FIGS. 1A–1C .
  • the elliptical orifice 120 has a minor diameter 124 shown in FIG. 2B , as well as a major diameter 122 shown in FIG. 2C . These diameters may be determined by positioning the port 150 at its desired height adjacent to the inflator body 111 and projecting the port 150 against the inflator body 111 . The distance between the points of intersection of the port 150 with the inflator body 111 is the diameter.
  • FIG. 2B shows an end view of the inflator 110 of FIG. 2A made using the welding method of the invention.
  • the view of FIG. 2B is shown by line 2 B— 2 B of FIG. 2A .
  • Both FIG. 2B and FIG. 2C help to show the characteristics of the weld 132 holding the port 150 and the inflator body 11 together.
  • the inflator 110 is seen to include a weld 132 .
  • the weld 132 has an external weld flash 128 and an internal weld flash 130 made up of thermoplastic material shed from the interface between the outlet port 150 and the contact edge (not shown, similar to 26 of FIG. 2C ) of the elliptical outlet orifice 120 .
  • the weld 132 is formed at the interface of the contact edge (not shown) of the elliptical outlet orifice 120 and the conical contact surface 162 of the outlet port 150 .
  • the conical contact surface 162 is a substantially smooth surface which is placed into contact with the contact edge (not shown) of the elliptical outlet orifice 120 during the welding method of the invention.
  • the conical contact surface 162 is defined by an included angle 167 .
  • the included angle 167 of the conical contact surface 162 may be varied widely within the scope of the invention. In some embodiments, the included angle 167 may be from about 30 degrees to about 90 degrees. In other embodiments, the included angle 167 may be from about 60 degrees to about 90 degrees.
  • the inflator 110 is shown in a longitudinal cross-section view taken at line 2 C— 2 C of FIG. 2B .
  • the inflator 110 includes an inflator body 111 having gas chambers 116 a and 116 b and a connecting chamber 118 and an outlet port 150 .
  • the inflator body 111 is sealed with end caps 112 a, 112 b which include initiator assemblies 114 a, 114 b.
  • the inflator body 111 includes an elliptical outlet orifice 120 provided in an outside surface of the inflator body 111 .
  • FIG. 2C illustrates a major diameter 122 of the outlet orifice 120 .
  • the outlet port 150 is attached to the inflator body 111 by a weld 132 between the outlet orifice 120 and the conical contact surface 162 .
  • the conical contact surface 162 of the outlet port 150 is defined by a single included angle 167 . In alternative embodiments of the invention, the conical contact surface 162 of the outlet port 150 is defined by multiple included angles.
  • a first embodiment of such an outlet port 250 is shown in FIG. 2D .
  • the outlet port 250 includes an outlet housing 252 and a port body 260 .
  • the outlet housing 252 includes outlet orifices 254 , and is attached to the port body 260 .
  • the port body 260 has an outlet passage 258 and a conical contact surface 262 .
  • the conical contact surface 262 has a large diameter 264 and a small diameter 266 .
  • the conical contact surface 262 of this outlet 250 is defined in this embodiment by a first included angle 267 a and by a second included angle 267 b.
  • the conical contact surface 262 here includes a transition 269 generally positioned in the contact face 268 of the contact surface 262 at which the defining included angle 267 a, 267 b is switched.
  • the contact surface 262 transitions from a wide included angle 267 a to a narrower included angle 267 b. In this embodiment, this results in a transition 269 which is a joint between a first portion of the conical contact surface 262 defined by the first included angle 267 a and a second portion of the conical contact surface 262 defined by the second included angle 267 b. In this embodiment, the portion of the conical contact surface 262 defined by the first included angle 267 a slopes gradually. After the transition 269 , however, the conical contact surface 262 slopes more steeply where it is defined by the second included angle 267 b.
  • FIG. 2E A second embodiment of an outlet port 350 having a conical contact surface 362 defined by multiple included angles 367 a, 367 b is shown in FIG. 2E .
  • the outlet port 350 includes an outlet housing 352 and a port body 360 .
  • the outlet housing 352 includes outlet orifices 354 , and is attached to the port body 360 .
  • the port body 360 has an outlet passage 358 and a conical contact surface 362 .
  • the conical contact surface 362 has a large diameter 364 and a small diameter 366 .
  • the conical contact surface 362 of this outlet 350 is defined in this embodiment by a first included angle 367 a and by a second included angle 367 b.
  • the conical contact surface 362 here includes a transition 369 generally positioned in the contact face 368 of the contact surface 362 at which the defining included angle 367 a, 367 b is switched.
  • the contact surface 362 transitions from a narrow included angle 367 a to a significantly wider included angle 367 b. This results in a transition 369 which is a joint between a first portion of the conical contact surface 362 defined by the first included angle 367 a and a second portion of the conical contact surface 362 defined by the second included angle 367 b.
  • the portion of the conical contact surface 362 defined by the first included angle 367 a slopes steeply.
  • the conical contact surface 362 slopes more gently where it is defined by the second included angle 267 b.
  • the welding methods of the invention may be employed to attach the outlet port 50 to the inflator body 11 of the inflator 10 by forming a weld 30 as shown in FIG. 1A .
  • the inflator 10 of FIGS. 1A , 1 B, and 1 C is welded using the method of the invention of joining a first tubular structure, here the outlet port 50 , to a second tubular structure, here the inflator body 11 .
  • the steps of this method will be discussed in detail hereafter.
  • the friction welding method of the invention generally includes the steps of providing a first component having a conical surface to be welded to a second component having an elliptical orifice placed in a tubular region of the second component.
  • the outlet port 50 with its conical contact surface 62
  • the inflator body 11 with its elliptical contact orifice 20
  • the orifice 20 may be provided using punching or stamping technologies known in the art.
  • the outlet port component 50 generally has a first axis of symmetry 70 shown in FIGS. 1A–1C .
  • the outlet port 50 may be rotated about this axis 70 .
  • the outlet port 50 has an axis of symmetry 70 passing through the center of the port component 50 .
  • This axis of symmetry 70 provides a stable axis of rotation for the outlet port 50 during the following steps of the method of the invention.
  • the inflator body component 111 is generally tubular in structure, and has an elliptical contact orifice 20 .
  • This elliptical contact orifice 20 is generally defined by a minor diameter 24 and a major diameter 22 , shown in FIGS. 1B and 1C , respectively.
  • the inflator body 111 is not necessarily symmetrical.
  • the conical contact face 62 of the outlet port 50 has a diameter 63 shown in FIG. 1C which ranges from a maximum size 64 at least as large as the major diameter 22 of the elliptical contact orifice 20 to a minimum size 66 smaller than the minor diameter 24 , while remaining at least as large as the minor diameter 24 of the elliptical contact orifice 20 .
  • the major and minor diameters 22 , 24 of the elliptical contact orifice 20 of the inflator body 11 may be determined by projecting the outlet port 50 against a side and an end of the inflator body 11 at the desired height of the outlet port 50 .
  • the first and second components here the outlet port 50 and the inflator body 11 , respectively, are aligned such that the outlet port 50 enters the elliptical outlet orifice 20 and the conical contact surface 62 is in contact with the edge 26 of the elliptical outlet orifice 20 .
  • the axis of symmetry 70 of the outlet port 50 is perpendicular to the major diameter 22 of the elliptical contact orifice 20 .
  • one of the two components 50 , 11 is rotated about the axis of symmetry 70 of the outlet port 50 , and the outlet port 50 is pressed against the inflator body 11 to form a weld 132 , shown in FIG. 2A .
  • the outlet port 50 is generally rotated about its axis of symmetry 70 and pressed against the inflator body 11 .
  • a weld such as 132 of FIG. 2A has formed, the rotation of the components 11 , 50 is ceased, and the structures 11 , 50 are retained in place to allow the weld 132 to cure.
  • the step of rotating one of the components 50 , 11 about the axis of symmetry 70 of the outlet port 50 includes rotating the outlet port 50 about the axis of symmetry 70 .
  • These methods generally further include the step of retaining the inflator body 11 in a fixed position while the outlet port 50 is being rotated.
  • the speed of rotation may be from about 6500 rpm to about 11,000 rpm. Alternatively, the speed of rotation may be from about 7500 rpm to about 10,000 rpm.
  • the outlet port 50 may be pressed against the inflator body 11 at a pressure of from about 900 psi–1200 psi.
  • the step of holding both of the tubular structures 50 , 11 in place to allow the weld 132 to cure may have a duration of at least about 0.5 seconds.
  • Weld energy and force may alternatively be used to describe the parameters needed during the step of rotating one of the components 50 , 11 about the axis of symmetry 70 of the outlet port 50 .
  • the broad range of suitable speeds of rotation noted above may be expressed as from about 4,655.95 foot-pounds of energy to about 13,334 foot-pounds.
  • the broad range of pressures used above may be expressed as from about 4,419 to about 5892.
  • the weld 132 is formed in two distinct steps: a step of rotation at a first rate and pressure; and a step of rotation at a decreased rate and an increased pressure.
  • the step of rotation at a first rate and pressure includes rotating one of the tubular structures 50 , 11 about the axis of symmetry 70 at from about 6350 rpm to about 9925 rpm.
  • the step of rotation at a first rate and pressure includes rotating one of the tubular structures 50 , 11 about the axis of symmetry 70 at from about 7350 rpm to about 8925 rpm.
  • the step of pressing the outlet port 50 against the inflator body 11 includes pressing the outlet port 50 against the inflator body 11 at from about 900 psi–1200 psi.
  • the step of pressing the outlet port 50 against the inflator body 11 is followed by the steps of reducing the rotation rate of the tubular structure being rotated and increasing the pressure of the outlet port 50 against the inflator body 11 .
  • the rotation rate of the tubular structure 50 , 11 being rotated may be reduced to from about 6000 rpm to about 9500 rpm.
  • the rotation rate of the tubular structure 50 , 11 being rotated may be reduced to from about 7000 rpm to about 8500 rpm.
  • the pressure of the outlet port 50 against the inflator body 11 may be increased to from about 1000 psi to about 1200 psi.
  • a method of friction welding for joining a tubular structure with a conical contact surface to an orifice placed in the side of a second tubular structure.
  • the second tubular structure has a flattened region into which the hole is placed. This method is illustrated with reference to an airbag inflator constructed using the method in FIG. 3 .
  • the airbag inflator 410 includes an outlet port 450 welded to an inflator body 411 .
  • the inflator body 411 includes gas chambers 416 a, 416 b that are interconnected by a central chamber 418 and capped by end caps 412 a, 412 b.
  • the generally rounded inflator body 411 includes a flattened region 415 .
  • the flattened region 415 has a width 417 which may be at least as large as, or equal to, a diameter of the outlet port 450 , especially a diameter at the level at which the flattened region 415 contacts the outlet port 450 .
  • the width 417 of the flattened region 415 is at least as large as or equal to the diameter of the outlet port 450 , and may be smaller than this diameter, ranging down to 0 in width, at which this method becomes equivalent to the methods of the invention described above.
  • the orifice 420 of the inflator body 411 is not elliptical in shape, as in previous methods of the invention. Instead, on those portions of the inflator body 411 which are rounded as above, the orifice 420 is generally elliptical in shape. In the flattened region 415 of the inflator body 411 , however, the orifice 420 has a rounded shape. Thus, in embodiments of this method in which the width 417 of the flattened region 415 is equal to or larger than the diameter of the outlet port 450 , the orifice 420 has a round/circular geometry.
  • the orifice 420 will have a constant radius, and thus a rounded shape along those regions where the orifice 420 was on the flattened region 415 , and an elliptical shape on the other regions.
  • the present invention provides methods of welding a first tubular component into the side of a second tubular component.
  • the first tubular structure is provided with a cone-shaped contact surface
  • the second tubular component is provided with an elliptical orifice for receiving the cone-shaped contact surface.
  • the components are friction welded together by rotating one of the components about an axis of symmetry of the first tubular structure while pressing both structures together.
  • One specific method of the invention is a method of welding an outlet port into an airbag inflator body to form an airbag inflator.
  • the outlet port generally includes an axis of symmetry about which it may be rotated.
  • the outlet port further includes a conical contact face.
  • the inflator body includes an elliptical outlet orifice sized to receive the conical contact face of the outlet port.
  • the conical contact face of the outlet port is first positioned by inserting it into the elliptical outlet orifice of the inflator body. Following this alignment step, one of the components is rotated about the axis of symmetry of the outlet port while the two components are pressed together. The speed of rotation and the pressure are selected to provide enough energy to the interface of the two components to soften the materials of the components and form a weld.
  • the methods of the invention provide a means for successfully joining a conical member to the side of another tubular member using friction welding.
  • the invention provides methods for friction-welding an outlet port into the inflator body of an airbag inflator. This helps to reduce the cost of assembling such airbag inflators, while allowing ease and speed of assembly.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Air Bags (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
US10/409,266 2003-04-08 2003-04-08 Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube Expired - Fee Related US6957761B2 (en)

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US10/409,266 US6957761B2 (en) 2003-04-08 2003-04-08 Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube
JP2006509738A JP4891067B2 (ja) 2003-04-08 2004-04-06 パイプまたはチューブ内に形成された楕円形状の孔内への円錐部材の慣性または摩擦溶接
DE112004000593T DE112004000593T5 (de) 2003-04-08 2004-04-06 Schwungradreibschweissen oder Reibschweissen konischer Komponenten in elliptisch geformte Löcher in einem Rohr oder in einer Röhre
PCT/US2004/010557 WO2004091840A2 (en) 2003-04-08 2004-04-06 Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube

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US20040070186A1 (en) * 2002-09-03 2004-04-15 Trw Airbag Systems Gmbh Method of producing a gas generator housing part, gas generator including such housing part and gas bag module
US20050230948A1 (en) * 2004-04-20 2005-10-20 Trw Vehicle Safety Systems Inc. Inflator with weld spatter collection
KR100689010B1 (ko) 2005-01-28 2007-03-08 우수이 고쿠사이 산교 가부시키가이샤 디젤 엔진용 커먼 레일
US11326730B2 (en) 2016-07-25 2022-05-10 Kongsberg Actuation Systems Ii, Inc. Support assembly

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US6957761B2 (en) * 2003-04-08 2005-10-25 Autoliv Asp, Inc. Inertia or friction welding of conical components into elliptically-shaped holes in a pipe or tube
DE202004017428U1 (de) * 2004-11-10 2005-01-27 Trw Airbag Systems Gmbh Gasgenerator und Gassackmodul
EP1848614A1 (en) * 2005-02-15 2007-10-31 Autoliv Development Aktiebolag Airbag inflator gas outlet and a method of manufacturing an airbag inflator
DE102005015788B3 (de) * 2005-04-06 2006-10-05 Trw Airbag Systems Gmbh Verfahren zur Herstellung eines Gasgenerators
DE102006041628A1 (de) * 2005-09-13 2007-04-19 Neumayer Tekfor Holding Gmbh Brennkammer sowie Verfahren zur Herstellung
JP4801509B2 (ja) * 2006-06-01 2011-10-26 近畿車輌株式会社 金属板の表面処理方法とそれを用いた車両
JP7165558B2 (ja) * 2018-10-19 2022-11-04 株式会社ダイセル 固定方法及びそれを用いたガス発生器のシールピン固定方法
US11597032B2 (en) * 2020-03-17 2023-03-07 Paul Po Cheng Method and system for modifying metal objects

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US20040070186A1 (en) * 2002-09-03 2004-04-15 Trw Airbag Systems Gmbh Method of producing a gas generator housing part, gas generator including such housing part and gas bag module
US7152321B2 (en) * 2002-09-03 2006-12-26 Trw Airbag Systems Gmbh Method of producing a gas generator housing part, gas generator including such housing part and gas bag module
US20050230948A1 (en) * 2004-04-20 2005-10-20 Trw Vehicle Safety Systems Inc. Inflator with weld spatter collection
KR100689010B1 (ko) 2005-01-28 2007-03-08 우수이 고쿠사이 산교 가부시키가이샤 디젤 엔진용 커먼 레일
US11326730B2 (en) 2016-07-25 2022-05-10 Kongsberg Actuation Systems Ii, Inc. Support assembly

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US20040200883A1 (en) 2004-10-14
JP2006522689A (ja) 2006-10-05
WO2004091840A3 (en) 2004-12-09
WO2004091840A2 (en) 2004-10-28
JP4891067B2 (ja) 2012-03-07

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